Composite Strip

ABSTRACT

A composite strip and a method of manufacturing a pre-cured composite strip. A pre-cured composite strip having a thermoset resin may be placed on a surface of a portion of a composite component where a caul plate seam may be expected. Caul plates may be placed on the composite component after placing the pre-cured composite strip to form the caul plate seam. The composite component may be cured after placing the caul plates on the composite component.

This application is a divisional of application Ser. No. 11/832,956,filed Aug. 2, 2007.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to composite components and inparticular to a method and apparatus for manufacturing compositecomponents. Still more particularly, the present disclosure relates to amethod and apparatus for improving the appearance of a compositecomponent.

2. Background

The aircraft are being designed and manufactured with greater andgreater percentages of composite materials. Some aircraft may have morethan fifty percent of its primary structure made from compositematerials. Composite materials may be used in aircraft to decrease theweight of the aircraft. This decreased weight may improve payloadcapacities and fuel efficiencies. Further, composite materials mayprovide longer service life for various components in an aircraft.

Composite materials may be tough, light-weight materials, created bycombining two or more dissimilar components. For example, a compositemay include fibers and resins. The fibers and resins may be combined toform a cured composite material.

Further, by using composite materials, portions of an aircraft may becreated in larger pieces or sections. For example, a fuselage in anaircraft may be created in cylindrical sections that may be put togetherto form the fuselage of the aircraft. Other examples may include withoutlimitation wing sections joined to form a wing or stabilizer sectionsjoined to form a stabilizer.

In creating composite components or structures with a curved or circularshape, the composite material may be shaped and/or laid up using a moldthat may be placed against an inner mold line (IML) of a compositecomponent. As a result, different features, textures, or appearances maybe created on the inner surface of the composite component and/orcomposite lay up using an inner mold that contacts the inner mold lineof the composite component. With a composite component in the form of afuselage for an aircraft, these features, textures, or appearances maybe used on the inside of a passenger cabin. These features, textures orappearances include, for example without limitation, windows, visiblelines framing a window for aesthetics, and textures on cabin walls.

In forming a composite component from composite material, the outersurface or outer mold line (OML) of the composite material may not besubject to an outer mold when an inner mold is used. In the case of asection of a fuselage, this outer mold line may provide the outsideappearance of the surface of the fuselage and/or barrel section. Withthis type of composite component, a smooth surface may be desired.

Depending on the size of the component, multiple caul plates may berequired to be placed on the outer surface of the composite componentduring curing or forming of the composite component. A caul plate may bea thin gauge sheet that may be made, without limitation, of a metal or acomposite material. These caul plates may be used to control the outermold line and create a smooth surface. Large composite components mayrequire multiple caul plates. When multiple caul plates are used, theseplates may be placed next to each other. A gap may be left betweenadjacent caul plates to accommodate caul plate thermal expansion of thecuring and/or heating processes during composite component fabrication.

At these edges of the caul plates, inconsistencies, such as a visiblemark off, fiber waviness and/or fiber distortion may occur. This markoff and fiber distortion may result in a visible line or seam. This typeof inconsistency may also occur if a vacuum bag contacts the compositematerial exposed in the gap between the caul plates and/or if the caulplates overlap during the curing process. Further, fiber waviness mayoccur with an unacceptable mark off or other type of inconsistency beingvisible on the cured composite and located in the gap between where thecaul plates were during cure. These types of inconsistencies may beundesirable.

Fillers and surfacing methods may be used to reduce the visibility ofthese inconsistencies. In other words, the fillers may separate from thecomposite component prior to the scheduled repainting of the surface ofthe aircraft. Further, the surface of the composite component may onlybe lightly sanded in preparation for painting. Excessive sanding mayresult in an undesirable appearance of the finished aircraft.

Currently, these types of inconsistencies in the aircraft may becontrolled by placing or locating caul plates such that the gaps inwhich inconsistencies may occur in locations on the aircraft that arenot clearly visible in the finished product. These gaps may also bereferred to as caul plate seams. For example, inconsistencies from caulplate seams located along a section of the fuselage where a wing isattached to the fuselage or the bottom of the fuselage may not be easilyvisible. Further, placing caul plates such that caul plate seams arealong cut out areas for windows may also minimize inconsistencies.

Accordingly, there is a need for a method and apparatus for minimizinginconsistencies appearing on the surface of a composite component, whichover comes the problems discussed above. Embodiments of the disclosureare intended to satisfy this need.

SUMMARY

An advantageous embodiment of the present disclosure provides a methodand apparatus for applying a pre-cured composite strip to a compositecomponent. A pre-cured composite strip having a thermoset resin may beplaced on a surface of a portion of the composite component where a caulplate seam may be expected. Caul plates may be placed on the compositecomponent after placing the pre-cured composite strip to form the caulplate seam. The composite component may be cured after placing the caulplates on the composite component.

In another advantageous embodiment, a pre-cured composite strip may bemanufactured by forming a composite strip may be formed. The compositestrip then may be cured to form the pre-cured composite strip.

Another advantageous embodiment may comprise a pre-cured compositestrip, a composite tape layer, and a second composite fabric layer. Thefirst composite fabric layer may have a first width. The composite tapelayer may be located on the composite fabric layer and may have a secondwidth that may be smaller that the first width. The second compositefabric layer may be located on the composite tape layer and may have athird width that may be smaller that the second width.

The features, functions, and advantages can be achieved independently invarious embodiments of the present disclosure or may be combined in yetother embodiments in which further details can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the advantageousembodiments are set forth in the appended claims. The advantageousembodiments themselves, however, as well as a preferred mode of use,further objectives and advantages thereof, will best be understood byreference to the following detailed description of an advantageousembodiment of the present disclosure when read in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a flow diagram of aircraft production and service methodologyin accordance with an advantageous embodiment;

FIG. 2 is a block diagram of an aircraft in accordance with anadvantageous embodiment;

FIGS. 3A-3D are an illustration of a method and apparatus forcontrolling mark off in fiber migration in a composite structure inaccordance with an advantageous embodiment;

FIG. 4 is an isometric view of a composite component in accordance withan advantageous embodiment;

FIG. 5 is an isometric view of a composite component after trim routingin accordance with an advantageous embodiment;

FIG. 6 is a cross-section view of a composite component with a compositestrip and caul plates in place in accordance with an advantageousembodiment;

FIG. 7 is an illustration of a cross-section view of layers in acomposite strip in accordance with an advantageous embodiment;

FIG. 8 is a cross-section view of a completed composite strip inaccordance with an advantageous embodiment;

FIG. 9 is a cross-section view of a composite strip in accordance withan advantageous embodiment;

FIG. 10 is an illustration of a cross-section view of another example ofa composite strip in accordance with an advantageous embodiment;

FIG. 11 is a flowchart of a process for creating a composite strip inaccordance with an advantageous embodiment; and

FIG. 12 is an illustration of a process for manufacturing a compositecomponent in accordance with an advantageous embodiment.

DETAILED DESCRIPTION

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 100 as shown in FIG. 1 and an aircraft 102 as shownin FIG. 2. During pre-production, exemplary method 100 may includespecification and design 104 of the aircraft 102 and materialprocurement 106. During production, component and subassemblymanufacturing 108 and system integration 110 of the aircraft 102 takesplace. Thereafter, the aircraft 102 may go through certification anddelivery 112 in order to be placed in service 114. While in service by acustomer, the aircraft 102 is scheduled for routine maintenance andservice 116 (which may also include modification, reconfiguration,refurbishment, and so on).

Each of the processes of method 100 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 2, the aircraft 102 produced by exemplary method 100may include an airframe 118 with a plurality of systems 120 and aninterior 122. Examples of high-level systems 120 include one or more ofa propulsion system 124, an electrical system 126, a hydraulic system126, and an environmental system 130. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of thedisclosure may be applied to other industries, such as the automotiveindustry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 100. Forexample, components or subassemblies corresponding to production process108 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 102 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 108 and 110, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 102. Similarly, one or more of apparatus embodiments, methodembodiments, or a combination thereof may be utilized while the aircraft102 is in service, for example and without limitation, to maintenanceand service 116.

The different advantageous embodiments may provide a method andapparatus for minimizing lines or other types of inconsistencies on thesurface of a composite component. In particular, these differentadvantageous embodiments may control, reduce, or minimizeinconsistencies, such as mark off and fiber migration to increase theaesthetic appearance of composite components.

In the different illustrative examples, inconsistencies caused by a caulplate seam between caul plates may be reduced by using a pre-curedcomposite. In these examples, the composite may be bonded and/or appliedto a substrate, which may be the composite component. The pre-curedcomposite may be a pre-cured composite strip placed on the outer moldline of the composite component prior to the application and/orplacement of the caul plates. The pre-cured composite strip may beplaced where, for example, a caul plate seam may occur between adjacentcaul plates.

In these examples, when cured, the pre-cured composite strip may besufficiently stiff to prevent the adjacent caul plates from forming aninconsistency in the composite component if these caul plates move orslide over the composite strip during the curing process. As a result,by allowing caul plate movement over the pre-cured composite strip,fiber and resin movement or other changes that may cause inconsistenciesmay be prevented. As a result, inconsistencies caused by caul platemovement during curing may be eliminated or reduced in extent to producea surface appearance that meets aesthetic requirements.

Further, the different illustrative examples may reduce out-of-planefiber waviness and increase the appearance quality of the surface of thecomponent. Out-of-plane fiber waviness may be an out-of-plane locationof fibers in an uncured ply stack up or cured part in which one or moreof the plies may be permanently cured into a ridge, depression, or foldnot consistent with part geometry. The out-of-plane direction may beeither away from or into the part.

Also, the different embodiments may reduce the need for filling thesurface of the component. Also, by using a pre-cured composite strip, alarger gap tolerance may be used in placing caul plates adjacent to eachother.

Turning now to FIGS. 3A-3D, an illustration of a method and apparatusfor controlling mark off in fiber migration in a composite structure isdepicted in accordance with an advantageous embodiment. In this example,composite component 300 may be a fuselage for an aircraft, such asfuselage 106 in aircraft 100 in FIG. 1. The construction or assembly ofcomposite component 300 may be performed during component andsubassembly manufacturing 108 during aircraft manufacturing and servicemethod 100 in FIG. 1.

In this example, the materials for composite component 300 are placedaround mold 302, or mold 302 may be placed into the inner mold lineportion of composite component 300. These materials may be, for examplewithout limitation, composite tape and/or composite fabric. Layers ofthese types and other types of composite materials may be laid down onto mold 302 to form composite component 300. In this example, mold 302is an inner mold that may contain features for an inner mold line ofcomposite component 300. Surface 304 is the surface for the outer moldline of composite component 300.

Next, composite strip 306 may be placed onto surface 304 of compositecomponent 300. In these examples, composite strip 306 may be a pre-curedcomposite strip. Further, composite strip 306 may be attached to surface304 of composite component 300 through an adhesive. For example, anadhesive film may be placed onto a surface of composite strip 306.Curing composite component 300 with composite strip 306 may cause theadhesive film and composite strip 306 to be integrated and/or attachedto composite component 300.

After the application of composite strip 306 to composite component 300,caul plates 308 and 310 may be placed onto composite component 300.These caul plates may be used to provide a smooth surface and to avoidinconsistencies from occurring that are not desired on surface 304 ofcomposite component 300.

Also, caul plate seam 312 may be present between caul plates 308 and310. Caul plate seam 312 may be a gap that is present between caulplates 308 and 310. The size of caul plate seam 312 may be selected totake into account different coefficients of expansion and compactionwhen composite component 300 is heated along with caul plates 308 and310. Composite strip 306 may result in a reduction and/or elimination ofinconsistencies in the area of caul plate seam 312 that may reduce thevisual aesthetics of composite component 300.

More specifically, depending on the material used to form caul plates308 and 310, these caul plates may expand at a different rate fromcomposite component 300. Further, composite component 300 may reduce indiameter during the curing process. As a result, caul plate seam 312,allows caul plate 308 and caul plate 310 to expand and/slide to avoidbuckling or hitting each other. Composite strip 306 may aid in reducinginconsistencies due to the expansion and/or sliding of caul plate 308and caul plate 310.

In this example, caul plates 308 and 310 may be placed such that caulplate seam 312 may run longitudely along composite component 300.Depending on the particular implementation, a caul plate seam may extendaround the circumference of composite component 300, rather thanlongitudinally, as depicted with caul plate seam 312.

Next, composite component 300 may be prepared for curing and placed intooven 314 with caul plates 308 and 310 in place. This assembly may becured by heating oven 314 to an appropriate temperature needed to curethe composite materials within composite component 300.

In these examples, oven 314 may be a composite curing oven in which heatand pressure may be applied to composite component 300 as the curingprocess occurs within oven 314. Oven 314 may provide temperatures ofaround three hundred fifty degrees to cure composite component 300. Inthese examples, oven 314 may be an autoclave that applies pressure andheat. Of course, any type of oven capable of curing composite parts maybe used in these different embodiments. In addition to using oven 314,other types of curing processes may be employed. For example, anelectron beam system may be used to cure composite components instead ofusing a thermal curing system, such as oven 314.

With reference now to FIG. 4, an isometric view of a composite componentis depicted in accordance with an advantageous embodiment. In thisexample, composite component 400 is an example of composite component300 in FIG. 3. In particular, composite component 400 may be an exampleof a fuselage section of an aircraft that has been cured in an oven,such as oven 314 in FIG. 3. In this example, pre-cured composite strips402, 404, and 406 may be present on surface 408 of composite component400. Pre-cured composite strips 402, 404, and 406 may be located insections or areas in which caul plate seams were present.

Turning now to FIG. 5, an isometric view of a composite component aftertrim routing is depicted in accordance with an advantageous embodiment.In this example, trim and routing processes may have been performed oncomposite component 400. This process may generate windows, such aswindows 500, 502, 504, 506, 508, 510 and 512. Additionally, passengerdoor trims 514 and 516 also may now be present after trim and routingprocesses have been performed on composite component 400. Although, inthese examples, pre-cured composite strips 402 and 406 may be aligned onthe windows, such an alignment may not be necessary.

Turning now to FIG. 6, a cross-section view of a composite componentwith a composite strip and caul plates in place is depicted inaccordance with an advantageous embodiment. In this example, compositecomponent 600 may be an example of a cross-section view for compositecomponent 300 in FIG. 3, taken along lines 6-6. In this example,composite strip 602 may be placed on surface 604 of composite component600. Composite strip 602 may be an example of composite strip 306 inFIG. 3. In this example, surface 604 is an outer surface for an outermold line of composite component 600. In this example, caul plates 606and 608 may be placed onto composite component 600 and composite strip602. Caul plates 606 and 608 may be an example of caul plates 308 and310 in FIG. 3.

In this example, caul plate seam 610 may be present between edge 612 ofcaul plate 606 and edge 614 of caul plate 608. In this example, caulplate seam 610 may have a ten millimeter gap. The size of the gap forcaul plate seam 610 may vary depending on factors, such as, for example,thermal expansion and/or the size of caul plates 606 and 608.

Further, in this particular illustrative example, composite strip 602may taper from center portion 616 to edges 618 and 620 of compositestrip 602. The amount of tapering that occurs may vary depending on theimplementation. The tapering in composite strip 602 may allow this stripto transition from enough plies to resist formation of inconsistenciesduring cure to a single ply. In these examples, each ply may be steppeddown in width such that the underlying plies may absorb the change instep without negative effect on the appearance of the compositecomponent. This may be driven by the thickness of the underlyinglaminate.

The width of the composite strip may be based on different factors, suchas, for example, the gap between the caul sheets, the method used toalign the pre-cured strip, or weight limitations. In these examples, onefactor in setting width of the pre-cured strip may be to use a fewestnumber of plies and a maximum thickness area that may completely supportthe edges of the caul sheet. Additionally, the thermal expansion andcompaction factors may be taken into account.

Turning now to FIG. 7, an illustration of a cross-section view of layersin a composite strip is depicted in accordance with an advantageousembodiment. In this example, composite strip 700 may be formed on baseplate 702. Base plate 702 may be a structure on which composite strip700 may be created. Further, composite strip 700 may be cured to form apre-cured composite strip on base plate 702 as described above. In thisparticular illustrative example, composite strip 700 may include peelply layer 704, composite fabric layer 706, composite tape layer 708,composite fabric layer 710, and peel ply layer 712.

Composite fabric layer 706 and composite fabric layer 710 both may bemade of the same type of materials or may be made from differentmaterials depending on the particular implementation. These fabrics mayinclude fibers and resins. The fibers may be, for example, carbonfibers. In these examples, the resins may be thermoset resins. Athermoset resin may be a resin that does not reflow or soften once ithas been cured. These composite fabric layers may be implemented usingany type of composite fabric in these examples.

Composite tape layer 708 also may be implemented using any type ofcomposite tape. In these particular examples, resin in composite tapelayer 708 also is a thermoset resin. In these examples, tape may consistof a series of unidirectional fibers that may become stiff in an outermold line direction that may be 90 degrees or perpendicular to the caulplate seam. This stiffness may be utilized to resist the caul sheetsforming inconsistencies in the pre-cured strips during the cure. Fibersthat run parallel to the caul plate seam may not resist the caul sheetsforming inconsistencies although some fibers may be in the direction ofthe seam to allow for handling of the pre-cured strip. In theseexamples, the fabric was chosen to match the rest of the surface of thecomposite component. Other applications may use tape as the outer ply.

In these examples, peel ply layer 704 and peel ply layer 712 may be usedto provide a surface prepared for a mechanical bond. In particular,these layers may provide a rough surface when removed from compositestrip 700. Peel ply layer 704 and peel ply layer 712 may be optionallayers. Alternatively, surfaces on composite strip 700 may be preparedfor mechanical bonding through other mechanisms, such as sanding orother surface preparation processes to obtain a clean rough surface.After curing composite strip 700, peel ply layer 704 may be removed.After removal of peel ply layer 704, an adhesive layer may be placedonto surface 714 of composite fabric layer 706. Peel ply layer 712 maybe removed after curing composite strip 700, and a surfacer layer may beplaced onto surface 716 of composite strip 700. The surfacer layer mayprovide a layer that will be sanded during the finishing of thecomposite component to feather or smooth composite strip 700 into theouter mold line of the composite component. In these examples, compositestrip 700 does not require being debalked using a vacuum bagging processprior to pre-cure.

In this example, composite strip 700 may be tapered with compositefabric layer 706 having a wider width than composite tape layer 708.Composite fabric layer 710 may have an even smaller width as compared tocomposite tape layer 708 and composite fabric layer 706.

In these particular examples, peel ply layer 704 and peel ply layer 712may have a width of around 3.0 inches. Composite fabric layer 706 mayhave a width of around 3.0 inches, and composite tape layer 708 may havea width of around 2.25 inches. Composite fabric layer 710 may have awidth of around 1.5 inches in these examples.

Turning now to FIG. 8, a cross-section view of a completed compositestrip is depicted in accordance with an advantageous embodiment. In thisexample, composite strip 700 from FIG. 7 now may include adhesive filmlayer 802 and surfacer layer 800. In this form, composite strip 700 maybe ready for application to an area or section where a caul plate seammay be expected or planned based on placement of caul plates.

Although composite strip 700 is illustrated with three layers ofcomposite materials, other numbers of layers of composite materials maybe used depending on the particular implementation. For example,composite strip 700 may have two layers comprising a composite fabriclayer and a composite tape layer. Alternatively, composite strip 700 mayhave more layers, such as four or five layers. The number of layers usedmay depend on the thickness desired with respect to the thicknessdesired for the composite strip. Typically, a thinner thickness may bedesired to reduce weight on the composite component. Also, the width ofcomposite strip 700 also may be selected based on the composite strip700 weight and gap size requirement.

In these examples, the composite materials used in composite strip 700may vary. In these examples, the composite materials used in compositestrip 700 may be ones that may not reflow or soften when reheated aftercuring. In particular, the composite materials may be made withthermoset materials or resins, which will not melt or soften after theinitial curing. In this manner, some stiffness may be present whenbonding the composite strip to the rest of the composite component. Thisstiffness may allow the caul plates to slide on the composite stripwithout causing inconsistencies in the appearance of the surface of thecomposite component. In this example, composite strip 700 may bepre-cured flat on surface 714 in FIG. 7. In other embodiments, compositestrip 700 may be pre-cured on a curved surface having a radius aroundthe same as the outer mold line for the fuselage section.

In particular, the different advantageous embodiments may be implementedto reduce or eliminate an appearance of inconsistencies resulting frommovement and/or expansion of adjacent caul sheets during the curing of acomposite structure or component in an aircraft.

Turning now to FIG. 9, a cross-section view of a composite strip isdepicted in accordance with an advantageous embodiment. In this example,composite strip 900 may be pre-cured prior to application or use on acomposite component.

In this example, composite strip 900 may include peel ply layer 902,tape layer 904, tape layer 906, fabric layer 908, and surfacer layer910. In this particular illustrative example, tape layer 904 may havethe smallest width. Tape layer 906 may have the second smallest width,and fabric layer 908 may have the largest width.

In this particular example, peel ply layer 902 may have a width ofaround 3.5 inches. Tape layer 904 may have a width of around 1.0 inch,and tape layer 906 may have a width of around 2.0 inches. Fabric layer908 may have a width of around 3.0 inches in this example. Surfacerlayer 910 may have a width of around 3.0 inches. Peel ply layer 902 maybe removed prior to application to a surface of a composite componentwith an adhesive layer being added.

With reference now to FIG. 10, an illustration of a cross-section viewof another example of a composite strip is depicted in accordance withan advantageous embodiment. In this example, composite strip 1000includes peel ply layer 1002, tape layer 1004, tape layer 1006, fabriclayer 1008, surfacer layer 1010, and peel ply layer 1012. In thisparticular example, peel ply layer 1012 may have a width of around 3.5inches. Surfacer layer 1010 may have a width of around 3.0 inches.Fabric layer 1008 may have a width of around 3.0 inches. Tape layer 1006may have a width of around 2.0 inches, and tape layer 1004 may have awidth of around 1.0 inch. Peel ply layer 1002 may have a width of around3.5 inches in this example.

The different types of layers and widths illustrated in FIGS. 7-10 areprovided for purposes of illustrating some different configurations thatmay be implemented. These examples are not meant to limit the manner inwhich layers may be selected or the widths. The different examplesillustrate one embodiment of layers of different widths to provide atapered composite strip for use in areas in which caul plate seams maybe expected. In these illustrative examples, the length of thesecomposite strips may be around 60 inches. Further, the zero degree plydirection may be parallel to the length of the composite strips in theseexamples. In these examples, one optimal utilization of the tapematerials may be when they are used with the fiber direction in theouter mold line plane that is 90 degrees or perpendicular to the lengthof a caul plate seam.

Some examples of materials that may be used in fabric and tape layersinclude, for example, without limitation, carbon, fiberglass, boron,ceramic, and aramids. The resins that may be found in these types oflayers may include, for example, alkyd polyester, epoxy,urea-formaldehyde, liquid-crystal, polytetrafluoroethylene,polyetheretherketone, and polyethersulfone. Adhesive film layers used inthe depicted examples may take the form of epoxy. With someresin/prepreg systems, an adhesive film is not required because theresin in the prepreg may be considered to be self-adhesive. Peel plylayers may be formed using nylon or polyester in the different examples.

In these examples, the fabric and tape may be prepreg components. Inother examples, the composite strips may be fabricated with resininfusion of dry fabric and/or tackified fabric.

Turning now to FIG. 11, a flowchart of a process for creating acomposite strip is depicted in accordance with an advantageousembodiment. The process illustrated in FIG. 11 may be used to create acomposite strip, such as composite strip 604 in FIG. 6 or compositestrip 700 in FIG. 7 or FIG. 8.

The process begins by selecting a composite material for a layer in thecomposite strip (operation 1100). Operation 1100 may include a selectionof the type of material and the dimensions for the material. A selectionof a fabric, tape, peel ply, or other material may be made. Thedimensions selected may include length, width, and thickness.

In this example, the first layer may take the form of a compositefabric. Of course, other types of composite materials may be used,depending on the implementation. In this example, the base may be abase, such as base plate 702 in FIG. 7. Depending on the implementation,the strip may be placed onto a strip or layer of peel ply that isalready present on the base. The selected strip of the compositematerial is placed onto a base to form a layer (operation 1102). Thestrip may be placed on top of another layer on the bases for layerssubsequent to the initial layer.

Next, the process determines whether additional layers may be needed forthe composite strip (operation 1104). If additional layers are needed,the process returns to operation 1100 to select another material for thenext layer of the composite strip. In selecting another layer, aselection of a fabric, tape, peel ply, surfacer, or other material maybe made. This selection may also include dimensions for this next layer.The width of this next layer may be narrower than a previous layer totaper the composite strip.

With reference again to operation 1104, if additional layers are notneeded, the process then cures the composite strip (operation 1106).Thereafter, the process terminates.

Turning now to FIG. 12, an illustration of a process for manufacturing acomposite component is depicted in accordance with an advantageousembodiment. The process illustrated in FIG. 12 may be used to create acomposite component, such as composite component 300 in FIG. 3.

The process begins by positioning a pre-cured composite strip over asurface of a composite component where a caul plate seam may be expected(operation 1200). Next, the pre-cured composite strip is bonded to thesurface of the composite component (operation 1202). The bonding may beachieved through the use of an adhesive layer, in these examples. Thecaul plate seam may be an area or section where a gap may be expectedbetween adjacent two caul plates placed onto the composite component.Next, the process places the caul plates onto the composite component(operation 1204). Then, process cures the composite component (operation1206) with the process terminating thereafter.

The different steps illustrated in FIG. 12 only depict some of the stepsinvolved in manufacturing a composite component with a desired amount ofsurface finish or appearance. Of course, other steps may be involved inpreparing the composite component both in forming the compositecomponent and preparing the composite component for curing.

Thus, the different advantageous embodiments provide a method andapparatus for applying a pre-cured composite strip to a compositecomponent. A pre-cured composite strip having a thermoset resin may beplaced on a surface of a portion of the composite component where a caulplate seam is expected. Caul plates may be placed on the compositecomponent after placing the composite strip to form the caul plate seam.The composite component may be cured after placing the caul plates onthe composite component.

In this manner, different advantageous embodiments may reduceinconsistencies on a finished composite component. The differentexamples depict features that may be found in some of all of theadvantageous embodiments. Different combinations of these features maybe used to reduce inconsistencies in the appearance of the surface ofcomposite components.

The description of the different advantageous embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. For example, the depicted embodiments mayapply the method and apparatus to the production of a compositefuselage. The different advantageous embodiments may be applied toreducing blemishes on other components or parts. For example, someadvantageous embodiments may be applied to other components, such as,without limitation, a wing or a tail of an aircraft. Further, differentadvantageous embodiments may provide different advantages as compared toother advantageous embodiments. The embodiment or embodiments selectedare chosen and described in order to best explain the principles of thedisclosure, the practical application, and to enable others of ordinaryskill in the art to understand the various embodiments with variousmodifications as are suited to the particular use contemplated.

1. A method of manufacturing a pre-cured composite strip, the methodcomprising: laying up the pre-cured composite strip; and curing thepre-cured composite strip.
 2. The method of claim 1, wherein the formingstep comprises: placing a layer of composite tape over a first layer ofcomposite fabric; and placing a second layer of composite fabric overthe layer of composite tape to form composite layers.
 3. The method ofclaim 2, wherein the forming step further comprises: placing a firstlayer of peel ply over the composite layers; and placing a second layerof peel ply under the composite layers.
 4. The method of claim 2,wherein the first layer of the composite fabric has a first width, thelayer of the composite tape has a second width that is less than thefirst width, and the second layer of the composite fabric has a thirdwidth that is less than the second width.
 5. The method of claim 1,wherein the pre-cured composite strip has a width and a length andwherein the pre-cured composite strip has a thickness that taperstowards opposing edges of the width of the pre-cured composite strip. 6.The method of claim 2, wherein the composite tape, the first layer ofthe composite fabric, and the second layer of the composite fabricinclude thermoset resins.
 7. The method of claim 3 further comprising:replacing the first layer of peel ply with an adhesive layer aftercuring the pre-cured composite strip; and replacing the second layer ofpeel ply with a surfacer layer after curing the pre-cured compositestrip.
 8. The method of claim 2, wherein the composite strip has athermoset resin.
 9. A composite strip comprising: a first compositefabric layer having a first width; a composite tape layer on the firstcomposite fabric layer having a second width that is smaller that thefirst width; and a second composite fabric layer on the composite tapelayer having a third width that is smaller that the second width. 10.The composite strip of claim 9, wherein the composite tape layer, thefirst composite fabric layer, and the second composite fabric layerinclude thermoset resins.
 11. The composite strip of claim 9, whereinthe composite strip is pre-cured.
 12. The composite strip of claim 9,wherein at least one of the composite tape layer, the first compositefabric layer, and the second composite fabric layer is a prepreg layer.